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Atlas Copco at Powtech: Hall 4, Stand 4-357
Low pressure: even more efficient bulk material handling with new compressors and blowers
At the Powtech trade fair, which is being held in Nuremberg in April, Atlas Copco is presenting new low-pressure compressors, as well as screw and lobe blowers for energy-efficient pneumatic conveyor systems. The ZE 3 S units compress air to gauge pressures of between 1.5 and 2.5 bar and are making their world debut at the trade fair. For applications up to 1.5 bar, the ZS 4 VSD+ screw blowers, which are 10 % more efficient than their predecessors, are ideal.
Essen, February 2019. From 9 to 11 April, Atlas Copco's stand at Powtech will highlight new technologies for the efficient handling of bulk materials for the food, chemical and pharmaceutical industries as well as applications in the construction materials sector (Hall 4, Stand 4-357). In Nuremberg, Atlas Copco will be presenting its new oil-free screw compressors in the ZE 3 S series for the first time.
The ZE 3 S deliver compressed air in the low pressure range from 1.5 to 2.5 bar gauge and are available with ratings from 37 to 90 kilowatts (kW). "They are about seven percent more efficient than their predecessors," says Dirk Villé, General Manager of Atlas Copco Kompressoren und Drucklufttechnik GmbH in Essen. "We have designed these units for a wide range of industrial applications in the fields of pneumatic conveyor systems and bulk materials handling." Villé sees potential customers especially in the cement, gypsum and glass industries, food and beverage production and the pharmaceutical industry. The units can also be used for unloading trucks carrying construction materials or flour, for example.
Atlas Copco has installed the latest oil free screw elements in its ZE 3 S compressors. They deliver air which is up to 100% oil-free in accordance with ISO 8573-1, class 0, for critical applications at extremely low life-cycle costs. The gear housing is extremely sturdy and the motor is fully encapsulated to degree of protection IP 55. It is therefore protected against penetration by dust. Thanks to the innovative design of these units, the initial investment is even lower than for the previous ZE and ZA compressors. "At the same time, we have improved the efficiency of these units by seven percent compared with the previous ZE 2 and ZE 3 models," Atlas-Copco manager Dirk Villé emphasizes.
Thanks to the compact plug and play design, the new ZE 3 S compressors are suitable for a variety of indoor and outdoor applications. Customers can change the scope of supplies flexibly for example by ordering a compressor without a motor or starter if they are OEMs and want to integrate the compressor into their own systems. The compressors are designed for operation at ambient temperatures between -20°C and +50°C.
New screw blowers for applications below 1.5 bar gauge
This year, the new ZS 4 VSD+ series screw blowers, with ratings from 37 to 90 kW, will be another highlight of Atlas Copco for the industry. These units also deliver oil-free compressed air but are designed for operating pressures below the values of the ZE, up to 1.5 bar. "The new ZS blowers combine our tried and tested screw technology with innovative components," General Manager Dirk Villé explains. "This way, we achieve high reliability and efficiency." The blowers supply TÜV-certified oil-free compressed air for pneumatic conveyor applications. "This new generation is one of the most energy-efficient solutions for oil-free screw blowers on the market, with guaranteed low life cycle costs," Villé reports.
IE5 permanent magnet motor reaches 97% efficiency
"These blowers have such a compact design that they take up only about half as much space as their predecessors with similar ratings," adds Dirk Villé. "This means that the blowers can be installed in any compressor room and can be easily positioned using a forklift truck." The high efficiency levels of the ZS 4 VSD+ are achieved thanks to features such as a specially coated rotor and a motor with efficiency class IE5. The new screw blowers are driven by a permanent magnet motor which has a virtually constant efficiency of 97% over the entire control range of the motor - also in part-load operation. The units are operated with Atlas Copco's latest variable speed drive technology (VSD+) which is significantly more efficient than the first generation of variable speed drives (VSD). This means that efficiency is increased even with fluctuating loads, reducing the energy consumption of the ZS blowers by up to 10% compared with their predecessors.
With the ZS 4 VSD+, pressure and temperature are continuously monitored, ensuring high reliability and efficiency. The screw blowers operate with a single-stage, direct-driven screw element and use up to 30% less energy than a lobe blower thanks to internal compression. Their wide control range means they can be used flexibly for many different processes. However, according to Villé, there are no generally applicable solutions for compressed air supply in bulk material handling. Each application needs to be reviewed individually. The actual requirements of the project determine the optimum compression technology. "An Air-Scan in advance of the project gives you the security you need for planning," Dirk Villé suggests. "During an Air-Scan, we measure the actual volume flow in operation, the compression required and the control ranges. We then simulate the system using modern compressor or blower units." The result is an overview indicating the savings potential in terms of kilowatt-hours and euros for the operator.
New oil-free lobe blowers for low initial investment
In Nuremberg, Atlas Copco is also exhibiting its economical ZL 2 VSD lobe blowers. "In physical terms, these units are not as efficient as screw blowers, but they are very inexpensive," says Dirk Villé. "In addition, the ZL units are extremely reliable and have very low maintenance requirements." Like the ZS 4 VSD+, the lobe blower delivers TÜV-certified absolutely oil-free compressed air in accordance with ISO 8573-1 class 0. The blower is supplied as a unit complete with controller and inverter. The inverter integrated in the system is programmed ready for use and adapted to the lobe blower. This makes installation easier for the user as there is no need for separate installation, wiring or programming of the inverter.
The ZL lobe blowers boost the air pressure by between 300 and 1000 mbar and are available with power requirements from 1.1 to 315 kW in finely graduated stages. However, Villé underlines that Atlas Copco generally recommends ZS screw blowers for pressure increases of 450 mbar and more: "The lower power costs justify the higher purchase price and the additional investment is recouped in a very short space of time."
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